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SONO-VARIO
User Manual
SONO-VARIOStandard for General Bulk Goods
SONO-VARIOXtrem for very high abrasive Goods like Gravel 4/32
and Grit
IMKO Micromodultechnik GmbH
Im Stöck 2
D - 76275 Ettlingen
Telefon:
Fax:
e-mail:
http:
+49 - (0)7243 - 5921 - 0
+49 - (0)7243 - 90856
[email protected]
//www.imko.de
I:\publik\TECH_MAN\TRIME-SONO\ENGLISH\SONO-VARIO\SONO-VARIO-Xtrem-MAN-Vers1_8-english.doc
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User Manual for SONO-VARIO
As of 1. August 2011
Thank you for buying an IMKO moisture probe.
Please carefully read these instructions in order to achieve best possible results with your
SONO-VARIO probe for the in-line moisture measurement. Should you have any questions
or suggestions regarding your new probe after reading, please do not hesitate to contact our
authorised dealers or IMKO directly. We will gladly help you.
List of Content:
1. Instrument Description SONO-VARIO ...................................................................................... 4 1.1.1. The patented TRIME® TDR-Measuring Method............................................................. 4 1.1.2. TRIME® compared to other Measuring Methods ........................................................... 4 1.1.3. Areas of Application with SONO-VARIOStandard and SONO-VARIOXtrem ................ 4 1.2. Mode of Operation ................................................................................................................. 5 1.2.1. Measurement value collection with pre-check, average value and filtering ................... 5 1.2.2. Determination of the mineral Concentration................................................................... 5 1.2.3. Temperature Measurement ............................................................................................ 5 1.2.4. Analogue Outputs........................................................................................................... 5 1.2.5. The serial RS485 interface ............................................................................................. 6 1.2.6. Error Reports and Error Messages ................................................................................ 6 1.3. Configuration of the Measure Mode ...................................................................................... 7 1.4. Operation Mode CA and CF at non-continuous Material Flow.............................................. 7 1.4.1. 1.5. Average Time in the measurement mode CA and CF ................................................... 9 Calibration Curves ................................................................................................................. 9 1.5.1. SONO-VARIO for measuring Moisture of Sand and Aggregates ................................ 12 1.5.2. SONO-VARIO for measuring Moisture of Expanded Clay and Lightly Sand ............... 13 1.6. Creating a linear Calibration Curve for a specific Material .................................................. 14 1.6.1. 1.7. Nonlinear calibration curves ......................................................................................... 14 Connectivity to SONO Probes ............................................................................................. 16 1.7.1. Connection Plug and Plug Pinning............................................................................... 17 1.8. Connection of the RS485 to the USB Module EXPERT ..................................................... 18 1.9. Connection of the RS485 to the SM-USB Module from IMKO ............................................ 19 2. Quick guide for the Software SONO-CONFIG ........................................................................ 21 2.1.1. Scan of connected SONO probes on the RS485 interface .......................................... 21 2.1.2. Configuration of Measure Mode ................................................................................... 22 2.1.3. Analogue outputs of the SONO probe ......................................................................... 22 2.1.4. 3/34
Selection of the individual Calibration Curves .............................................................. 23 2.1.5. Test run in the respective Measurement Mode ............................................................ 24 2.1.6. Basic Balancing in Air and Water.................................................................................. 25 3. Installation of the Probe............................................................................................................ 26 3.1. Assembly Instructions .......................................................................................................... 26 3.2. Assembly Dimensions ..........................................................................................................27 3.3. Mounting in curved Surfaces ................................................................................................ 29 3.4. Gas- and waterproofed Installation ...................................................................................... 30 3.5. Exchange of the Probe Head of the VARIOXtrem ............................................................... 31 3.5.1. Basic Balancing of a new Probe Head.......................................................................... 32 4. Technical Data SONO-VARIO ................................................................................................... 33 4/34
1. Instrument Description SONO-VARIO
1.1.1. The patented TRIME® TDR-Measuring Method
The TDR technology (Time-Domain-Reflectometry) is a radar-based dielectric measuring procedure
at which the transit times of electromagnetic pulses for the measurement of dielectric constants,
respectively the moisture content are determined.
SONO-VARIO consists of a high grade steel casing with a wear-resistant sensor head with ceramic
window. An integrated TRIME TDR measuring transducer is installed into the casing. A high
frequency TDR pulse (1GHz), passes along wave guides and generates an electro-magnetic field
around these guides and herewith also in the material surrounding the probe. Using a new patented
measuring method, IMKO has achieved to measure the transit time of this pulse with a resolution of
1 picosecond (1x10-12), consequently determine the moisture and the conductivity of the measured
material.
The established moisture content, as well as the conductivity, respectively the temperature, can
either be uploaded directly into a SPC via two analogue outputs 0(4) ...20 mA or recalled via a
serial RS485 interface.
1.1.2. TRIME® compared to other Measuring Methods
In contrary to conventional capacitive or microwave measuring methods, the TRIME® technology
(Time-Domain-Reflectometry with Intelligent Micromodule Elements) does not only enable the
measuring of the moisture but also to verify if the mineral concentration specified in a recipe has
been complied with. This means more reliability at the production.
TRIME-TDR technology operates in the ideal frequency range between 600MHz and 1,2 GHz.
Capacitive measuring methods (also referred to as Frequency-Domain-Technology) , depending on
the device, operate within a frequency range between 5MHz and 40MHz and are therefore prone to
interference due to disturbance such as the temperature and the mineral contents of the measured
material. Microwave measuring systems operate with high frequencies >2GHz. At these frequencies,
nonlinearities are generated which require very complex compensation. For this reason, microwave
measuring methods are more sensitive in regard to temperature variation.
SONO probes calibrate themselves in the event of abrasion due to a novel and innovative probe
design. This consequently means longer maintenance intervals and, at the same time, more precise
measurement values.
The modular TRIME technology enables a manifold of special applications without much effort due
to the fact that it can be variably adjusted to many applications.
1.1.3. Areas of Application with SONO-VARIOStandard and SONO-VARIOXtrem
SONO-VARIO is suited for installation into containers, hoppers and silos.
 The SONO-VARIOStandard is suited for measuring of normal abrasive materials. The probe head
consists of stainless steel with a rectangular ceramic window.
 The SONO-VARIOXtrem is suited for measuring of very high abrasive materials like gravel 4/32 and
grit. The probe head consists of hardened steel with a rectangular special ceramic window.
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1.2. Mode of Operation
1.2.1. Measurement value collection with pre-check, average value and filtering
SONO-VARIO measures internally at a rate of 100 measurements per seconds and issues the
measurement value at a cycle time of up to 200 milliseconds at the analogue output. In these 200
milliseconds a probe-internal pre-check of the moisture values is already carried out, i.e. only plausible
and physically pre-averaged measurement values are be used for the further data processing. This
increases the reliability for the recording of the measured values to a downstream control system
significantly.
In the Measurement Mode CS (Cyclic-Successive), an average value is not accumulated and the
cycle time here is 200 milliseconds. In the Measurement Mode CA and CF (Average), not the
momentarily measured individual values are directly issued, but an average value is accumulated via a
variable number of measurements in order to filter out temporary variations. These variations can be
caused by inhomogeneous moisture distribution in the material surrounding the sensor head. The
delivery scope of SONO-VARIO includes suited parameters for the averaging period and a universally
applicable filter function deployable for currently usual applications. The time for the average value
accumulation, as well as various filter functions, can be adjusted for special applications.
1.2.2. Determination of the mineral Concentration
With the radar-based TRIME measurement method, it is now possible for the first time, not only to
measure the moisture, but also to provide information regarding the conductivity, respectively the
mineral concentration or the composition of a special material. Hereby, the attenuation of the radar
pulse in the measured volume fraction of the material is determined. This novel and innovative
measurement delivers a radar-based conductance value (RbC – Radar-based-Conductivity) in dS/m
as characteristic value which is determined in dependency of the mineral concentration and is issued
as an unscaled value. The RbC-measurement range of the SONO-VARIO is 0..12dS/m
1.2.3. Temperature Measurement
A temperature sensor is installed into the SONO-VARIO which establishes the casing temperature
3mm beneath the sensor surface. The temperature can optionally be issued at the analogue output 2.
As the TRIME electronics operates with a power of approximately 1.5 W, the probe casing does
slightly heat up. A measurement of the material temperature is therefore only possible to a certain
degree. The material temperature can be determined after an external calibration and compensation of
the sensor self-heating.
1.2.4. Analogue Outputs
The measurement values are issued as a current signal via the analogue output. With the help of the
service program SONO-CONFIG, the SONO-VARIO can be set to the two versions for 0..20mA or
4..20mA. Furthermore, it is also possible to variably adjust the moisture dynamic range e.g. to 0-10%,
0-20% or 0-30%. For a 0-10V DC voltage output, a 500R resistor can be installed in order to reach a
0..10V output.
Analogue Output 1: Moisture in % (0…20%, variable adjustable)
Analogue Output 2: Conductivity (RbC) or optionally the temperature.
In addition, there is also the option to split the analogue output 2 into two ranges: into
4..11mA for the temperature and 12..20mA for the conductivity. The analogue output
2 hereby changes over into an adjustable one-second cycle between these two
(current) measurement windows.
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For the analogue outputs 1 and 2 there are thus two adjustable options:
Analog Output: (two possible selections)
0..20mA
4..20mA
Output Channel 1 and 2: (three possible selections)
1. Moist, Temp. Analogue output 1 for moisture, output 2 for temperature.
or
2. Moist, Conductivity Analogue output 1 for moisture, output 2 for conductivity in
a range of 0..20dS/m.
or
3. Moist, Temp/Conductivity Analogue output 1 for moisture, output 2 for
both, temperature and conductivity with an automatic current-window change.
For analogue output 1 and 2 the moisture dynamic range and temperature dynamic
range can be variably adjusted. The moisture dynamic range should not exceed
100%
Moisture Range:
Maximum: e.g. 20 for sand (Set in %)
Minimum: 0
Temp. Range:
Maximum: 100 °C
Minimum: 0 °C
1.2.5. The serial RS485 interface
SONO-VARIO is equipped with a standard RS485 interface to serially readout individual parameters
or measurement values. An easy to implement data transfer protocol enables the connection of
several sensors/probes at the RS485-Interface. In addition, the SONO-VARIO can be directly
connected to the USB port of a PC, in order to adjust individual measuring parameters or conduct
calibrations, via the RS485 USB Module which can be provided by IMKO.
1.2.6. Error Reports and Error Messages
SONO-VARIO is very fault-tolerant. This enables failure-free operation. Error messages can be
recalled via the serial RS485 interface.
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1.3. Configuration of the Measure Mode
The configuration of SONO-VARIO is preset in the factory before delivery. A process-related later
optimisation of this device-internal setting is possible with the help of the service program SONOCONFIG. For all activities regarding parameter setting and calibration the probe can be directly
connected via the RS485 interface to the PC via a RS485 USB-Module which is available from IMKO.
The following settings of SONO-VARIO can be amended with the service program SONO-CONFIG:
Measurement-Mode and Parameters:

Measurement Mode A-On-Request (only in network operation for the retrieval of
measurement values via the RS485 interface).
 Measurement Mode C Cyclic:
SONO-VARIO is supplied ex factory with suited parameters in Mode CS for bulk goods.
Mode CS: (Cyclic-Successive) For very short measuring processes (e.g. 5…20 seconds)
without floating average, with internal up to 100 measurements per second and a cycle time of
250 milliseconds at the analogue output. Measurement mode CS can also be used for getting
raw data from the SONO-probe without averaging and filtering.
Mode CA: (Cyclic-Average-Filter) For relative short measuring processes with continual
average value, filtering and an accuracy of up to 0.1%
Mode CF: (Cyclic-Float-Average) for continual average value with filtering and an accuracy of
up to 0.1% for very slowly measuring processes, e.g. in fluidized bed dryers, conveyor belts,
etc.
Mode CK: (Cyclic-Kalman-Filter) Standard setting for SONO-MIX for use in fresh concrete
mixer with continual average value with special dynamic Kalman filtering and an accuracy of
up to 0.1%.
 Calibration (if completely different materials are deployed)
Each of these settings will be preserved after shut down of the probe and is therefore stored on a
permanent basis.
1.4. Operation Mode CA and CF at non-continuous Material Flow
For mode Ca and CF the SONO-VARIO is supplied ex factory with suited parameters for the
averaging time and with a universally deployable filter function suited for most currently applications.
The setting options and special functions of the SONO-VARIO depicted in this chapter are only rarely
required. It is necessary to take into consideration that the modification of the settings or the
realisation of these special functions may lead to faulty operation of the probe!
For applications with non-continuous material flow, there is the option to optimise the control of the
measurement process via the adjustable filter values Filter-Lower-Limit, Filter-Upper-Limit and the time
constant No-Material-Keep-Time. The continual/floating averaging can be set with the parameter
Average-Time.
Detection of malfunctions at the probe head
SONO-VARIO is able to identify, if temporarily no or less material is at the probe head and can filter
out such inaccurate measurement values (Filter-Lower-Limit). Particular attention should be directed
at those time periods in which the measurement area of the probe is only partially filled with material
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for a longer time, i.e. the material (sand) temporarily no longer completely covers the probe head.
During these periods (Lower-Limit-Keep-Time), the probe would establish a value that is too low. The
Lower-Limit-Keep-Time sets the maximum possible time where the probe could determine
inaccurate (too low) measurement values.
Furthermore, the passing or wiping of the probe head with metal blades or wipers can lead to the
establishment of too high measurement values (Filter-Upper-Limit). The Upper-Limit-Keep-Time
sets the maximum possible time where the probe would determine inaccurate (too high) measurement
values.
Using a complex algorithm, SONO-VARIO is able to filter out such faulty individual measurement
values. The standard settings in the Measurement Mode CA and CF for the filter functions depicted
in the following have proven themselves to be useful for many applications and should only be altered
for special applications.
Parameters in the Measurement
Mode CA, CF and CK
Function
Average-Time
Standard Setting: 10
Setting Range: 1…20
The time (in seconds) for the generation of the
average value can be set with this parameter.
Filter-Upper-Limit-Offset
Standard Setting: 5
Setting Range: 1….20
With the setting of 20, this parameter
must be disabled for Mode CK !
Too high measurement values generated due to
metal wipers or blades are filtered out. The
offset value in % is added to the dynamically
calculated upper limit.
Filter-Lower-Limit
Standard Setting: 2
Setting Range: 1.….20
With the setting of 20, this parameter
must be disabled for Mode CK !
Too low measurement values generated due to
insufficient material at the probe head are
filtered out. The offset value in % is subtracted
from the dynamically calculated lower limit with
the negative sign.
Upper-Limit-Keep-Time
Standard Setting: 5
Setting Range: 1...100
With the setting of 100, this parameter
must be disabled for Mode CK !
The maximum duration (in seconds) of the filter
function for Upper-Limit-failures (too high
measurement values) can be set with this
parameter.
Lower-Limit-Keep-Time
Standard Setting: 30
Setting Range: 1...100
With the setting of 100, this parameter
must be disabled for Mode CK !
The maximum duration (in seconds) of the filter
function for Lower-Limit-failures (too low
measurement values) for longer-lasting
"material gaps", ie the time in which no material
is located on the probe, can be bridged.
Kalman Filter-Parameter in
Measurement Mode CK:
Q-Parameter
Standard Setting: 1x10-5
Setting Range: 0.01…1x10-7
This Kalman filter parameter Q is used to
characterize the systemic measurement error. It
is recommended to leave this parameter to the
default setting!
R-Parameter
Standard Setting: 0.033
Setting Range: 0.01 ….. 0.1
This Kalman filter parameter R is used for
smoothing the measurement error. The lower
this parameter, the faster is the response to
smaller changes in the moisture readings. The
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higher this parameter is the more smoothed the
measured value, but with a delayed reaction
time. It is recommended to leave this parameter
to the default setting!
K-Parameter
Standard Setting: 0.01
Setting Range: 0.01 ….. 0.2
This Kalman filter parameter K is used for a predynamic behaviour of the Kalman Filter for
higher changes in the moisture reading, i.e. the
reaction rate of the measurement signal can be
affected hereby. The K-parameter is related to
the Average-Time. It is recommended to leave
this parameter to the default setting!
1.4.1. Average Time in the measurement mode CA and CF
SONO-VARIO establishes every 200 milliseconds a new single measurement value which is
incorporated into the continual averaging and issues the respective average value in this timing cycle
at the analogue output. The averaging time therefore accords to the “memory” of the SONO-VARIO.
The longer this time is selected, the more inert is the reaction rate, if differently moist material passes
the probe. A longer averaging time results in a more stable measurement value. This should in
particular be taken into consideration, if the SONO-VARIO is deployed in different applications in order
to compensate measurement value variations due to differently moist materials.
At the point of time of delivery, the Average Time is set to 4 seconds. This value has proven itself to be
useful for many types of applications. At applications which require a faster reaction rate, a smaller
value can be set. Should the display be too “unstable”, it is recommended to select a higher value.
1.5. Calibration Curves
SONO-VARIO is supplied with a universal calibration curve for sand (Cal1: Universal Sand Mix). A
maximum of 15 different calibration curves (CAL1 ... Cal15) are stored inside the SONO probe and
can optionally be activated via the program SONO-CONFIG.
A preliminary test of an appropriate calibration curve (Cal1. .15) can be activated in the menu
"Calibration" and in the window “Material Property Calibration" by selecting the desired calibration
curve (Cal1...Cal15) and with using the button “Set Active Calib”. The finally desired and possibly
altered calibration curve (Cal1. .15) which is activated after switching on the probes power supply will
be adjusted with the button "Set Default Calib”.
Nonlinear calibrations are possible with polynomials up to 5th grade (coefficients m0...m5).
IMKO publish on its website more suitable calibration coefficients for different materials. These
calibration coefficients can be entered and stored in the SONO probe by hand (Cal14 and Cal15) with
the help of SONO-CONFIG.
The following charts (Cal.1 .. 15) show different selectable calibration curves which are stored inside
the SONO probe.
Plotted is on the y-axis the gravimetric moisture (MoistAve) and on the x-axis depending on the
calibration curve the associated radar time tpAve in picoseconds. With the software SONO-CONFIG
the radar time tpAve is shown on the screen parallel to the moisture value MoistAve (see "Quick
Guide for the Software SONO-CONFIG).
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1.5.1. SONO-VARIO for measuring Moisture of Sand and Aggregates
The TRIME-TDR technology with the radar method offers high reliability for measuring moisture of
sand and aggregates, as different grain sizes, unlike other measurement techniques such as
microwave technology, do not cause any distortion of the measurement result.
The calibration curve Cal1 "Universal Sand Mix" is suitable for measuring the moisture in bulk sand,
gravel and gravel/sand granulates. The deviations to the universal calibration curve Cal1 are
approximately +-0.5%, depending on the moisture range, for the below listed gravel/sand types.
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1.5.2. SONO-VARIO for measuring Moisture of Expanded Clay and Lightly Sand
Concerning the material density, expanded clay and lightly sand differ significantly in comparison to
sand and gravel. Therefore a separate calibration for each material is necessary. It is to consider that
expanded clay below a moisture level of 12% still can absorb more water, ie here it must be calculated
with more addition of water into a mixture. At moisture levels above 12% (the maximum core moisture
of expanded clay), the surface water of the expanded clay would act as a free addition of water and
the addition of water into a mixture should be reduced.
For measuring these two materials the probe calibration Cal10 or Cal11 can be selected.
If you want to use a single SONO probe with the calibration Cal1 for both normal sand/gravel as well
as these two materials, then there is the possibility with a simple mathematical conversion inside a
PLC. Requirement would be that the PLC knows when and what material is to be measured. You may
convert the following:
MoistureLightlySand
= MeasurementValueCal1 * Factor of 4
MoistureExpandedClay = MeasurementValueCal1 * Factor of 4.8 + 3.2 Offset
It is to consider that this correction calculation for expanded clay can only be measured above 3.2%,
which in practice would be acceptable as it is unlikely that in plant operation the moisture in expanded
clay is below 3.2%.
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1.6. Creating a linear Calibration Curve for a specific Material
The calibration curves Cal1 to Cal15 can be easily created or adapted for specific materials with the
help of SONO-CONFIG. Therefore, two measurement points need to be identified with the probe.
Point P1 at dried material and point P2 at moist material where the points P1 and P2 should be far
enough apart to get a best possible calibration curve. The moisture content of the material at point P1
and P2 can be determined with laboratory measurement methods (oven drying). It is to consider that
sufficient material is measured to get a representative value.
Under the menu "Calibration" and the window "Material Property Calibration" the calibration curves
CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes
max. 1 minute). With the mouse pointer individual calibration curves can be tested with the SONOprobe by activating the button "Set Active Calib". The measurement of the moisture value
(MoistAve) with the associated radar time tpAve at point P1 and P2 is started using the program
SONO-CONFIG in the sub menu "Test" and "Test in Mode CF" (see "Quick Guide for the Software
SONO- CONFIG").
Step 1: The radar pulse time tpAve of the probe is measured with dried material. Ideally, this takes
place during operation of a mixer/dryer in order to take into account possible density fluctuations of the
material. It is recommended to detect multiple measurement values for finding a best average value
for tpAve. The result is the first calibration point P1 (e.g. 70/0). I.e. 70ps (picoseconds) of the radar
pulse time tpAve corresponds to 0% moisture content of the material. But it would be also possible to
use a higher point P1´ (e.g. 190/7) where a tpAve of 190ps corresponds to a moisture content of 7%.
The gravimetric moisture content of the material, e.g. 7% has to be determined with laboratory
measurement methods (oven drying).
Step 2: The radar pulse time tpAve of the probe is measured with moist material. Ideally, this also
takes place during operation of a mixer/dryer. Again, it is recommended to detect multiple
measurement values of tpAve for finding a best average value. The result is the second calibration
point P2 with X2/Y2 (e.g. 500/25). I.e. tpAve of 500ps corresponds to 25% moisture content. The
gravimetric moisture content of the material, e.g. 25% has to be determined with laboratory
measurement methods (oven drying).
Step 3: With the two calibration points P1 and P2, the calibration coefficients m0 and m1 can be
determined for the specific material (see next page).
Step 4: The coefficients m1 = 0.0581 and m0 = -4.05 (see next page) for the calibration curve Cal14
can be entered directly by hand and are stored in the probe by pressing the button “Set”. The name of
the calibration curve can also be entered by hand. The selected calibration curve (e.g. Cal14) which is
activated after switching on the probes power supply will be adjusted with the button "Set Default
Calib”.
Attention: Use “dot” as separator (0.0581), not comma !
1.6.1. Nonlinear calibration curves
SONO probes can also work with non-linear calibration curves with polynomials up to 5th grade.
Therefore it is necessary to calibrate with 4…8 different calibration points. To calculate nonlinear
coefficients for polynomials up to 5th grade, the software tool TRIME-WinCal from IMKO can be used
(on request). It is also possible to use any mathematical program like MATLAB for finding a best
possible nonlinear calibration curve with suitable coefficient parameters m0 to m5 which can be
entered into the probe with help of SONO-CONFIG.
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The following diagram shows a sample calculation for a linear calibration curve with the coefficients
m0 and m1 for a specific material.
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1.7. Connectivity to SONO Probes
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1.7.1. Connection Plug and Plug Pinning
SONO-VARIO is supplied with a 10-pole MIL flange plug.
.
Assignment of the 10-pole MIL Plug and sensor cable connections:
Plug-PIN
Sensor Connections
Lead Colour
A
+7V….28V Power Supply
red
B
0V
blue
D
1. Analogue Positive (+)
Moisture
green
E
1. Analogue Return Line (-)
Moisture
yellow
F
RS485 A
white
G
RS485 B
brown
C
(rt) IMP-Bus
(grey/pink)
J
(com) IMP-Bus
(blue/red)
K
2. Analogue Positive (+)
pink
E
2. Analogue Return Line (-)
grey
H
Screen
(is grounded at the sensor. The plant
must be properly grounded!)
transparent
Power Supply
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1.8. Connection of the RS485 to the USB Module EXPERT
SONO-VARIO is equipped with a standard RS485 interface to serially readout individual parameters
or measurement values. An easy to implement data transfer protocol enables the connection of
several sensors/probes on the RS485-Interface. In addition, the SONO-VARIO can be directly
connected to the USB port of a PC, in order to adjust individual measuring parameters or conduct
calibrations, via the RS485 to USB-Module EXPERT which can be provided by IMKO.
How to start with the USB-Module EXPERT EX9531
 Install USB-Driver CDM 2.04.06.exe from USB-Stick.
 Connect the EX9531 to the USB-Port of the PC and the installation will be accomplished
automatically.
 Install Software SONOConfig-SetUp.msi from USB-Stick.
 Connection of the SONO probe to the EX9531 via RS485A, RS485B and 0V.
 Check the setting of the COM-Ports in the Device-Manager und setup the specific COM-Port with
the Baudrate of 9600 Baud in SONO-CONFIG with the button "Bus" and "Configuration" (COM1COM15 is possible).
 Start “Scan probes” in SONOConfig.
 The SONO probe logs in the window „Probe List“ after max. 30 seconds with its serial number.
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1.9. Connection of the RS485 to the SM-USB Module from IMKO
The SM-USB provides the ability to connect a SONO probe either to the standard RS485 interface or
optionally to the IMP-Bus from IMKO, which enables the download of a new firmware to the SONO
probe. Both connector ports are shown in the drawing below.
The SM-USB is signalling the status of power supply and the transmission signals with 4 LED´s. When
using a dual-USB connector on the PC, it is possible to use the power supply for the SONO probe
directly from the USB port of the PC without the use of the external AC adapter.
How to start with the USB-Module SM-USB from IMKO
 Install USB-Driver from USB-Stick.
 Connect the SM-USB to the USB-Port of the PC and the installation will be accomplished
automatically.
 Install Software SONOConfig-SetUp.msi from USB-Stick.
 Connection of the SONO probe to the EX9531 via RS485A, RS485B and 0V.
 Check the setting of the COM-Ports in the Device-Manager und setup the specific COM-Port with
the Baudrate of 9600 Baud in SONO-CONFIG with the button "Bus" and "Configuration" (COM1COM15 is possible).
 Start “Scan probes” in SONOConfig.
 The SONO probe logs in the window „Probe List“ after max. 30 seconds with its serial number.
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Note 1:
In the Device-Manager passes it as follows:
Control Panel  System  Hardware  Device-Manager
Under the entry “Ports (COM & LPT) now the
item “USB Serial Port (COMx)” is found.
COMx set must be between COM1….COM9 and it should be ensured that there is no double
occupancy of the interfaces.
If it comes to conflicts among the serial port or the USB-SM has been found in a higher COM-port, the
COM port number can be adjusted manually:
By double clicking on "USB Serial Port" you can go into the properties menu, where you see
"connection settings" – with "Advanced" button, the COM port number can be switched to a free
number.
After changing the COMx port settings, SONO-CONFIG must be restarted.
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2. Quick guide for the Software SONO-CONFIG
With SONO-CONFIG it is possible to make process-related adjustments of individual parameters of
the SONO probe. Furthermore the measurement values of the SONO probe can be read from the
probe via the RS485 interface and displayed on the screen.
In the menu "Bus" and the window "Configuration" the PC can be configured to an available COMxport with the Baudrate of 9600 Baud.
2.1.1. Scan of connected SONO probes on the RS485 interface
In the menu "Bus" and the window "Scan Probes" the RS485 bus can be scanned for attached
SONO probes (takes max. 30 seconds).
SONO-CONFIG reports founded SONO probes with its serial number in the window “Probe List“.
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2.1.2. Configuration of Measure Mode
In "Probe List" with "Config" and "Measure Mode & Parameters” the SONO probe can be adjusted
to the desired mode CA, CF or CS (see Chapter “Configuration Measure Mode”).
2.1.3. Analogue outputs of the SONO probe
In the menu "Config" and the window "Analog Output" the analogue outputs of the SONO probe can
be configured (see Chapter “Analogue outputs..”).
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2.1.4. Selection of the individual Calibration Curves
In the menu "Calibration" and the window "Material Property Calibration" the calibration curves
CAL1 to Cal15 which are stored in the SONO probe are loaded and displayed on the screen (takes
max. 1 minute). With the mouse pointer individual calibration curves can be activated and tested with
the SONO-probe by activating the button "Set Active Calib". Furthermore, the individual calibration
curves CAL1 to Cal15 can be adapted or modified with the calibration coefficients (see Chapter
“Creating a linear calibration curve”).
The desired and possibly altered calibration curve (Cal1. .15) which is activated after switching on the
probes power supply can be adjusted with the button "Set Default Calib”.
The coefficients m1 = 0.0581 and m0 = -4.05 for individual calibration curves can be entered and
adjusted directly by hand and are stored in the probe by pressing the “Set” button.
Attention: Use “dot” as separator (0.0581), not comma !
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2.1.5. Test run in the respective Measurement Mode
In the menu "Test" and the window "Test in Mode CA or CF" the measured moisture values
“MoistAve” (Average) of the SONO probe are displayed on the screen and can be parallel saved in a
file.
In the menu "Test" and the window "Test in Mode CS" the measured single measurement values
“Moist” (5 values per second) of the SONO probe are displayed on the screen and parallel stored in a
file. In „Test in Mode A“ single measurement values (without average) are displayed on the screen
and can also be stored in a file.
Attention: for a test run in mode CA, CF, CS or A it must be ensured that the SONO probe was also
set to this mode (Measure Mode CA, CF, CS, A). If this is not assured, the probe returns zero values.
Following measurement values are displayed on the screen:
MoistAve
Moisture Value (Average)
MatTemp
Temperature
Conduct
Radar-based-Conductivity RbC
TDRAve
TDR-Level (for special applications)
DeltaCount
Number of single measurements which are used for the averaging.
tpAve
Radar time (average) which corresponds to the respective moisture value.
By clicking „Save“ the recorded data is saved in a text file in the following path:
\SONO-CONFIG.exe-Pfad\MD\Dateiname
The name of the text file Statis+SN+yyyymmddHHMMSS.sts is assigned automatically with the
serial number of the probe (SN) and date and time.
The data in the text file can be evaluated with Windows-EXCEL.
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2.1.6. Basic Balancing in Air and Water
SONO probe heads are identical and manufactured precisely. After an exchange of a probe head it is
nevertheless advisable to verify the calibration and to check the basic calibration and if necessary to
correct it with a “Basic Balancing”.
With a “Basic Balancing” two reference calibration measurements are to be carried out with known setpoints ("RefValues"). For the reference media, air and water (tap water) can be used.
Attention: Before performing a “Basic Balancing” it must be ensured that the SONO probe was set to
“Measure Mode” A. If this is not assured, the probe returns zero values. After a “Basic Balancing” the
SONO probe has to be set to “Measure Mode C” again.
In the menu "Calibration" and the window "Basic Balancing" the two set-point values of the radar
time tp are displayed with 60ps and 1000ps.
1. Reference set-point A: tp=60ps in air (the surface of the probe head must be dry!!)
The first set-point can be activated with the mouse pointer by clicking to No.1. By activating
the button "Do Measurement" the SONO probe determines the first reference set-point in air.
In the column „MeasValues“ the measured raw value of the radar time t is displayed (e.g.
1532.05 picoseconds).
2. Reference set-point B: tp=1000ps in water. The SONO probe head has to be covered with
water in a height of about 50mm. The second set-point can be activated with the mouse
pointer by clicking to No.2. By activating the button "Do Measurement" the SONO probe
determines the second reference set-point in water. In the column „MeasValues“ the
measured raw value of the radar time t is displayed.
3. By activating the button „Calculate Coeffs“ and „Coeffs  Probe“ the alignment data is
calculated automatically and is stored in the SONO probe non-volatile. With a “Test run” (in
Mode A) the radar time tp of the SONO probe should be now 60ps in air and 1000ps in water.
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3. Installation of the Probe
The installation conditions are strongly influenced by the constructional circumstances of the
installation facility. The ideal installation location must be established individually. The following
guidelines should hereby be observed.
3.1. Assembly Instructions
The following instructions should be followed when installing the probe:
 The installation locations may not be situated beneath the inlets for additives.
 In case of an uneven base, the probe must be installed at the highest point of the base. No
water may accumulate at the probe head as this could falsify the measurement.
 Areas with strong turbulences are not ideal for the installation. There should be a continuous
material flow above the probe head.
 The stirring movement of blades should be conducted without gap above the probe head.
 The probe should not be installed in the direct vicinity of electrical disturbing sources such as
motors.
 In case of curved installation surfaces in containers, the centre of the probe head should be
flush with the radius of the container wall without disturbing the radial material flow in the
container. The probe may not project and come in contact with blades or wipers.
Attention! Risk of Breakage!
The probe head is made of hardened special steel and a very wear-resistant ceramic in order to
warrant for a long life-span of the probe. In spite of the robust and wear-resistant construction, the
ceramic plate may not be exposed to any blows as ceramic is prone to breakage.
In case of welding work at the plant, all probes must be completely electrically
disconnected.
Any damage caused by faulty installation is not covered by the warranty!
Abrasive wear of sensor parts is not covered by the warranty!
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3.2. Assembly Dimensions
SONO-VARIO can either be installed at the base or the side wall of containers. One fact to
consider is that the installation into the container base also enables the measurement of smaller
material quantities. A mounting flange is available for SONO-VARIO. The flange can both be
welded on to the base and the side wall of the container. The probe can be adjusted to the
correct position, respectively correct installation height.
SONO-VARIOStandard:
SONO-VARIOXtrem:
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Dimensions of the Mounting Flange
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3.3. Mounting in curved Surfaces
In order to prevent the probe head from projecting and interfering with wipers, the centre of the
probe head should be flush with the radius of the wall. The ceramic must be laterally aligned to
the rotational axis as the gap towards the wipers is smallest in this position.
In order to ensure that the probe head is completely covered with material, the probe is best
positioned near the base. In order to prevent water from accumulating above the sensor head,
which could falsify the measurement, an installation angle of approximately 30° above the base
centre is recommended.
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3.4. Gas- and waterproofed Installation
For a pressure-tight installation in a temperature range from -20 ° C to +80 ° C, a flange kit is
available (on request). The mounting flange can be welded to the container wall. Sealing is done
with a 5.5mm thick O-ring which is fixed with a locking ring.
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3.5. Exchange of the Probe Head of the VARIOXtrem
At the SONO-VARIOXtrem not only the ceramic plate but the whole metal/ceramic wear-resistant probe
head can be exchanged.
This is how easy it is to exchange the wear-resistant probe head of the SONO-VARIO:
- Loosen the 4 fastening screws (look for the right sequence of washer and gasket rings).
- Lift off the probe head carefully so that the robust spring contacts in the interior are canted as
little as possible.
- Clean the surface inside the probe body for the O-Ring.
- Place on the probe head so that the two spring contacts are inserted in the contact bushings.
- Screw the 4 fastening screws back on. It is to consider, that the 4 screws “find” the 4 holes in the
green epoxy plate inside the probe.
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3.5.1. Basic Balancing of a new Probe Head
The probe heads are all identical and are manufactured to fit precisely. In spite of this fact, after an
exchange it is necessary to make a basic calibration in air and water, that SONO-MIX measures
precise and accurate with the new probe head. Therefore some work-steps are required.
Basic calibration procedure:
1. Provide a small container with water in which the probe head can be plunged in. For the first
calibration point in air the probe head must be completely dry. If appropriate dry it with a towel.
2. Unplug the blind cap of the calibration connector and plug in the calibration connector.
3. Plug in the MIL-connector with power supply to the probe. The blue LED is on for 3 seconds and
start with a slow blinking for the next 10 seconds preparation time for the first point in air.
Therefore the dry probe head must be free in air. When the LED is on continual for 5 seconds the
calibration is completed in air.
4. Now the blue LED starts with a quicker blinking during 10 seconds preparation time for the
second point in water. During this 10 seconds the probe head must plunged in water. When the
LED is on continual for 5 seconds the calibration is completed in water. After that the LED is off.
5. If the calibration should be failed, the blue LED will be blinking continual.
6. Unplug the MIL connector and the calibration connector. Plug in the blind cap of the calibration
connector. Plug in the MIL connector again. The blue LED should be on continual now. SONOMIX is ready to use. With strong pressing of a hand to the probe head, the analogue moisture
output 4..20mA should be respond.
If necessary the basic balancing procedure could be repeated several times.
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4. Technical Data SONO-VARIO
SENSOR DESIGN
Casing: High Grade Steel V2A 1.4301
SONO-VARIOStandard: The probe head surface consists of stainless steel with
abrasion-resistant aluminium oxide ceramic.
SONO-VARIOXtrem: The probe head surface consists of hardened steel with
highly abrasion-resistant special ceramic.
High-temperature versions up to 150°C with external measurement transformer
SONO-ES are available upon request!
MOUNTING
Sensor Dimensions:
SONO-VARIOStandard: 108 x 45mm (Diameter x Length)
SONO-VARIOXtrem: 108 x 71mm (Diameter x Length)
The mounting flange can be screwed on to the rear side of any container, hopper or silo.
MEASUREMENT RANGE MOISTURE
The sensor measures from 0% up to the point of material saturation. Measurement
ranges up to 90% moisture are possible with a special calibration.
MEASUREMENT RANGE CONDUCTIVITY
The sensor, as a material-specific characteristic value, delivers the radar-based conductance
(RbC – Radar-based-Conductance) in a range of 0…12dS/m. The conductivity range is reduced
in measurement ranges >50%.
MEASUREMENT RANGE TEMPERATURE
Measurement Range: 0°C …100°C
The temperature is measured 3mm beneath the wear-resistant sensor head inside the
sensor casing and is issued at the analogue output 2. The material temperature can be
measured with an external calibration and compensation of the sensor intrinsic-heating.
MEASUREMENT DATA-PREPROCESSING
MEASUREMENT MODE CA: (Cyclic-Average) For relative short measuring processes with
continual average value, filtering and an accuracy of up to 0.1%
MEASUREMENT CF: (Cyclic-Float-Average) For very slow measuring processes with
floating average value, filtering and an accuracy of up to 0.1%
MEASUREMENT MODE CS: (Cyclic-Successive) For very short measuring processes
without floating average with internal up to 100 measurements per second and a cycle time of
200 milliseconds at the analogue output.
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SIGNAL OUTPUT
2 x Analogue Outputs 0(4)…20mA
Analogue Output 1: Moisture in % (0..20% variably adjustable)
Analogue Output 2: Conductivity (RbC) 0..20dS/m, or optionally the temperature.
In addition, there is the option to split the analogue output 2 into two ranges: into
4..11mA for the temperature and 12..20mA for the conductivity. The analogue output
2 hereby changes over into an adjustable 5 second cycle between these two
(current) measurement windows.
The two analogue outputs can be variably aligned with the SONO-CONFIG software.
For a 0-10V DC voltage output, a 500R resistor can be installed.
CALIBRATION
The sensor is provided with a universal calibration for sand. A maximum of 15
different calibrations can be stored. For special materials, variable calibrations with
polynomials up to the 5th order are possible. A zero point correction can be performed
easily with the SONO-CONFIG software.
COMMUNICATION
A RS485 interface enables network operation of the probe, whereby a data bus
protocol for the connection of several SONO probes to the RS485 is implemented by
default. The connection of the probe to industrial busses such as Profibus, Ethernet,
etc. is possible via optional external modules (available upon request).
POWER SUPPLY
+7V to +28V DC, 1.5 W max.
AMBIENT CONDITIONS
0 - 70°C
A higher temperature range is available upon request!
MEASUREMENT FIELD EXPANSION
Approximately 50 - 80 mm, depending on material and moisture.
CONNECTOR PLUG
The sensor is equipped with a robust 10-pole MIL flange connector. Ready made connection
cables with MIL connectors are available cable lengths of 4m, 10m, or 25 m.